Retractable roof panel

ABSTRACT

A vehicle is provided that includes a roof with a roof opening and a rear body portion with a rear opening. Spaced apart guide rails are supported on an exterior surface of the roof. A retractable roof panel is supported on the guide rails by guide members that move along the guide rails along a path. The roof opening and the roof panel extend to the rearward end where the roof panel defines a rear header. The retractable roof panel may be driven from a closed positioned forward to an open position where the roof panel is adjacent to the exterior surface of the roof. The rear gate assembly, which is arranged in the rear opening, may be opened to provide access to the rear cargo area of the vehicle. With the rear gate assembly and retractable roof panel open, large items may be slid into the cargo area and may extend above the plane of the roof.

RELATED APPLICATIONS

[0001] This application is a continuation of U.S. Ser. No. 10/316,527filed Dec. 11, 2002, which is a continuation-in-part of U.S. applicationSer. No. 09/989,361 filed Nov. 20, 2001 now U.S. Pat. No. 6,494,528,which is a continuation-in-part of U.S. patent application Ser. No.09/876,519, filed Jun. 7, 2001 and also claims priority to ProvisionalApplication No. 60/252,238, filed Nov. 20, 2000.

BACKGROUND OF THE INVENTION

[0002] This invention relates to a roof assembly for a vehicle, and moreparticularly, the invention relates to a retractable roof panel thatincludes the rear header of the vehicle for providing improved access tothe rear cargo area of the vehicle when the roof panel is retracted.

[0003] Sunroofs are desireable features to many vehicle customers.Sunroofs are typically arranged in an area above the driver and frontpassenger seats. The sunroof maybe be retracted to expose the interiorof the vehicle to the environment and permit air and light to enter thevehicle. Typically, the opening for the sunroof is relatively small, andsunroofs have not been used to provide increased access to the interiorof the vehicle. They have simply been used to provide a more pleasantdriving experience to the vehicle occupants.

[0004] Once sunroofs are moved from the closed position to an openposition, the sunroof is typically stowed in a area between the interiorof the roof structure and an interior trim headliner. That is, thesunroof is stowed using the interior space of the vehicle such that itimpinges upon the passenger's headroom. The larger the vehicle sunroof,the more problematic it may become to stow the sunroof. Significantvehicle design changes may be required to maintain occupant headroom. Asa result, it is desireable to stow a sunroof in the open position insuch a manner that interior space is not reduced.

[0005] Prior art sunroof assemblies have utilized rails located on theexterior of the roof for storing the sunroof outside of the vehicle.These prior art assemblies have incorporated a roller assembly receivedin a guide track in the rails. However, the rails lack means to keepdebris from entering the guide tracks and inhibiting the operation ofthe roller assemblies. Even without debris inhibiting the properoperation of the sunroof, the large size of the sunroof makes itdifficult for the sunroof to move desirably within the rails withoutbinding.

[0006] Therefore, what is needed is a sunroof that does not impinge uponpassenger headroom or reduce the interior space in the vehicle.Furthermore, what is needed is a sunroof that provides increased accessto the cargo area within the vehicle such that loading and unloading ofthe vehicle is simplified and larger cargo items may be placed insidethe vehicle.

SUMMARY OF THE INVENTION AND ADVANTAGES

[0007] The present invention provides a vehicle having a roof with aroof opening and a rear body portion with a rear opening. Spaced apartguide rails are supported on an exterior surface of the roof. Aretractable roof panel is supported on the guide rails by guide membersthat move along the guide rails along a path. The roof opening and theroof panel extend to the rearward end where the roof panel defines arear header. The retractable roof panel may be driven from a closedposition forward to an open position where the roof panel is adjacent tothe exterior surface of the roof. The rear gate assembly, which isarranged in the rear opening, may be opened to provide access to therear cargo area of the vehicle. With the rear gate assembly andretractable roof panel open, large items may be slid into the cargo areaand may extend above the plane of the roof.

[0008] The guide members move along a path defined by the guide rails.The guide member includes a roller assembly received within a channel ineach of the guide rails and a bracket connected to the roller assemblysupporting a drive cable. A bracket as supported on the roller assemblyand is rotatable relative thereto. The roller assembly includes a flangeand the bracket includes a stop of the flange engaging the stop causingthe roller assembly and brackets to rotate together. As the rollerassembly and its two lower rollers travel along the longitudinal guiderail into the curved portion of the support members connecting the railsto the roof, the roller assembly forces the bracket to rotate with it,which bends the drive cable to prevent it from binding within thesupport member and rails. The roller assembly may also include a rollerbiased in an upper direction against a ceiling of the guide rail tovertically locate the sunroof as it moves along the rail and reducenoise and vibration. Seals may be used in the guide rail to seal thedrive cable and any wires in a compartment away from debris.

[0009] Accordingly, the above invention provides a sunroof that does notimpinge upon passenger headroom or reduce the interior space in thevehicle. Furthermore, a sunroof is provided that increases access to thecargo area within the vehicle such that loading and unloading of thevehicle is simplified and larger cargo items may be placed inside thevehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Other advantages of the present invention can be understood byreference to the following detailed description when considered inconnection with the accompanying drawings wherein:

[0011]FIG. 1 is a rear perspective view of the present invention vehiclewith the rear window partially open;

[0012]FIG. 2 is a rear perspective view of the present invention vehiclewith the window partially open and the rear gate assembly pivoted upwardto an open position;

[0013]FIG. 3 is a rear perspective view of the present invention vehiclewith the tailgate of the rear gate assembly pivoted downward;

[0014]FIG. 4 is a front perspective view of the present inventionretractable roof in a closed position;

[0015]FIG. 5 is a front perspective view of the present inventionretractable roof in an open position;

[0016]FIG. 6 is a front perspective view of the present invention roofassembly;

[0017]FIG. 7 is an enlarged perspective view of a guide member and guiderail with front roller mechanism;

[0018]FIG. 8 is an exploded view of the guide rail and guide membershown in FIG. 7;

[0019]FIG. 9 is a perspective view of the guide member roller mechanism;

[0020]FIG. 10 is a perspective view of the guide member bracketassembly;

[0021]FIG. 11a is a cross-sectional view of roof panel in the closedposition;

[0022]FIG. 11b is a cross-sectional view of the roof panel in apartially open position;

[0023]FIG. 11c is a cross-sectional view of the roof panel moving towardthe open position;

[0024]FIG. 12 is a cross-sectional view of a rear guide member;

[0025]FIG. 13 is a cross-sectional view of the present invention guidemember in the rail;

[0026]FIG. 14 is a perspective view of the inside of the guide memberpartially disposed in the rail;

[0027]FIG. 15 is a perspective side view of the guide member and railshown in FIG. 14; and

[0028]FIG. 16 is a perspective view of the outside of the guide memberand rail.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0029] A vehicle 10 utilizing the present invention is shown in FIGS.1-3. The vehicle 10 shown has a four-door body 12 that includes A, B, C,D pillars. The body 12 has a roof 14 that includes the present inventionretractable roof panel 16. The roof panel 16 has a rear header 17, whichmay commonly be referred to as a D pillar header for the four-doorvehicle shown. A wiper 19 may be mounted to the rear header 17.

[0030] A rear body portion 18 defines a rear opening 20. A rear gateassembly 22 is mounted on the rear body portion 18 to enclose the rearopening 20. The gate assembly 22 may include a frame 28 supporting alower body or tail gate 26 and a window 24. However, it is to beunderstood that any arrangement may be used for the rear gate assembly22. As shown in FIG. 1, the window 24 may be lowered from an upperboundary 21 defined by the rear header 17 into the lower body 26 toprovide partial access to the cargo area 30 or for manipulating the roofpanel 16 during opening and closing. As shown in FIG. 2, the window andtailgate 26 may move pivotally upward with the frame 28 to act as a liftgate. For configurations in which the wiper 19 is mounted to the rearheader 17, the window 24 may be partially opened to ensure clearance ofthe wiper 19. As shown in FIG. 3, the frame 28 may remain secured to therear body portion 18 to manipulate the tail gate 26. The window 24 maybe lowered into the tail gate 26, and the tail gate may be rotateddownward to permit access to the cargo area 30 of the interior cabin sothat objects may be easily slid into the rear of the vehicle. It can beappreciated that the present invention vehicle, as shown in FIGS. 1-3,functions to permit cargo of a relatively limited height to be stored inthe cargo area 30 of the vehicle 10.

[0031] Referring to FIGS. 4-6, the roof 14 may be provided by a roofassembly 36 that may be secured to the rest of the vehicle body duringassembly of the vehicle 10. The roof assembly 36 may include all of thefeatures discussed below in addition to other features and interior trimsuch as head liner and dome lights, etc. The roof assembly 36 includesthe roof 14 that defines a generally U-shaped roof opening 37, best seenin FIG. 5. The roof panel 16 is a rigid unitary structure that ispreferably constructed from a fiber reinforced polymer material. Theroof 14 may also be a fiber reinforced polymer material or may bestamped steel. The roof assembly 36 has a perimeter 39 of which the rearheader 17 defines the rearward end 54 of the perimeter 39. The roof 14includes guide rails 40 that define a path of the roof panel 16. Theguide rails 40 are mounted to the exterior surface 38 of the roof 14.The guide rails include longitudinal members 42 that are secured to theroof 14 by support members 44. Luggage racks 48 may be arrangedlaterally between the guide rails 40.

[0032] A wind deflector 46 may be arranged at a forward end 47 of theroof 14 to direct wind over the roof panel 16 when the roof panel 16 isin the open position, as shown in FIG. 5. A motor 50 may be mounted onthe exterior surface 38 of the roof 14 beneath the wind deflector 46.Drive cables 52 may be coupled to a portion of the roof panel 16 andconnected to the motor 50 driving the roof panel 16 between the closedposition (shown in FIG. 4) and the open position (shown in FIG. 5). Thecables 52 may have a helical outer member typical of the type used insunroofs.

[0033] The roof panel 16 of the present invention is stowed on theoutside of the vehicle 10 adjacent to the exterior surface 38. Theforward portion 49 of the roof panel 16 may be arranged partially underthe wind deflector 46 with the roof panel 16 beneath the luggage racks48. Unlike typical sunroof assemblies, the present invention roof panel16 moves from the rearward end 54 of the vehicle to the forward end 47of the vehicle. Additionally, the roof panel 16 includes the rear header17 such that when the roof panel 16 is moved to the open position andthe rear gate assembly 22 is moved to the open position very large itemsthat may extend beyond the plane of the roof 14 may be placed easilyinto the cargo area 30.

[0034] Referring to FIG. 6, the roof panel 16 is shown supporting theforward portion 49 in the guide rails 40 by guide members 60. Rear guidemember 62 support the rear of the roof panel 16 on the roof 14, whichwill be discussed in more detail below. The forward portion of the roofopening 37 includes a first wall portion 64. The forward portion 49 ofthe roof panel 16 includes a second wall portion 65 that is adjacent tothe first wall portion 64 when the roof panel 16 is in the closedposition. A latch assembly 66 is mounted underneath the wall portions 64and 65. The latch may be arranged in any suitable location. The latchassembly 66 locks the roof panel 16 to the roof 14 when the roof is inthe closed position. Preferably, two spaced apart latch assembly 66 areused to reduce the stress on the roof panel 16.

[0035] Referring to FIGS. 7-9, the forward guide members 60 are receivedwithin the center support members 44. The guide members 60 travel alonga path in the longitudinal members 42 and support members 44 defined bya channel 74. For the embodiment shown, the rear longitudinal members 42are for aesthetics and do not support the roof panel 16. As shown inFIG. 8, the support member 44 includes a pocket 70 received in a recessin the roof 14 (not shown) and sealed thereto by a gasket 72. As theroof panel 16 moves from the closed position to the open position theguide members 60 travel up along the channel 74 defined in the supportmember 44 to raise the forward portion 49 of the roof panel 16. Thelongitudinal 42 and support 44 members are secured to one another usinga tongue 76 and groove 78 arrangement and fasteners (now shown). Thedrive cables 68 and wires 69 may be routed through the channel 74 andcarried by a portion of the guide member 60. The wires may be routed toa rear brake light and/or the wiper 19.

[0036] Referring to FIG. 9, a guide member 60 includes a cage 80 thatcarries a pair of first rollers 82 rotatable about horizontal axles andsecond rollers 84 rotatable about vertical axes. The first rollers 82carry the load of the roof panel 16 on the bottom of the channel 74. Thesecond rollers 84 may ride a long a side of the channel 74 to take upany lateral clearance and guide the roof in the tracks as it movesbetween the open and closed positions. However, it is to be understoodthat any number and configuration of rollers may be used. The cage 80includes a lateral member 86 that extends from the cage 80 to a block 88that is secured to the roof panel 19. The lateral member 86 may includea damper to further minimize roof panel vibrations.

[0037] A bracket 90 having a generally vertical elongated aperture 92 isarranged between the cage 80 and the roof panel 16 with the lateralmember 86 disposed within the aperture 92. The aperture 92 permits therollers 82 and 84 and cage 80 to move upward if the first rollers 82must travel over debris trapped on the bottom of the channel 74. Abiasing member 94 or spring normally urges the lateral member 86downward in the aperture 92. Opposing ends 95 of the spring 94 areretained with retaining pockets 97. The drive cable 68 and wires 69 maybe respectively mounted on cable 96 and wire 98 mounts secured to thebracket 90. The motor 50 pulls the roof panel 16 forward to the openposition. The roof panel 16 is closed by pushing it and lowering itunder the force of its own weight.

[0038] A rear guide member 62 is best shown in FIGS. 11a-11 c and 12.Unlike the forward guide member 60, the rear guide members 62 do notride within the guide rails 40. However, it is to be understood that therear guide member 62 may be configured such that they do ride within theguide rails 40 similar to the guide members 60. The rear guide member 62rides along a rear aperture, which may defined by the roof assembly 36or another portion of the vehicle 10, and a drain trough 106 which isdefined by a channel arranged about the perimeter roof opening 37, whichis best shown in FIG. 12. The rear guide member 62 includes a bracket108 secured to the roof panel 16. The bracket 108 pivotally supports anarm 110 having rollers 112. A spring 114 biases the arm 110 forward awayfrom the rear header 17. Referring to FIG. 11a, the roof panel 16 isshow in a closed and locked position in which the arm 110 is tiltedrearward with a roller 112 received in a recess 118 in the rear aperture104. In this position, the rear of the roof panel 16 cannot be lifteduntil the roof panel is moved forward. As the roof panel 16 is movedforward, as shown in FIG. 11b, the arm 110 rotates forward as the roofpanel 16. The spring 114 urges the arm 110 to unseat one of the rollers112 from the recess 118. As the roof panel 16 continues to move forward,as shown in FIG. 11c, the rollers 112 move along the drain trough 106.The rear guide member 62 configuration provides enough lift to the rearof the roof panel 16 such that the roof panel 16 may clear the exteriorsurface 38 of the roof 14 when in the fully opened position.

[0039] In operation, the rear gate assembly 22 may be manipulated asdescribed in relation to FIGS. 1-3 above to permit access to the cargoarea 30. However, when increased access to the cargo area 30 is desired,for example for cargo items having a height that exceeds the plane ofthe roof 14, the roof panel 16 may be retracted. To retract the roofpanel 16, the latch assembly 66 must be actuated to unlock the forwardportion 49 of the roof panel 16 from the roof 14. The forward guidemember 60 will begin to move up the channel 74 in the support member 44,and the rear guide member 62 will rotate forward such that one of therollers 112 moves out of engagement with the recess 118. The forwardguide member 60 will move along the channels 74 within the longitudinalmember 42, and the rear guide member 62 and will move along the draintrough 106. The forward portion 49 of the roof panel 16 will preferablybe disposed beneath wind deflector 46. Preferably when opening theretractable roof panel 16, the window 24 will be lowered into the lowerbody 26 to minimize the force on the window 24 when traveling along aroad with the retractable roof panel 16 in the open position.

[0040]FIGS. 13-16 are directed to improvements of the guide member 60 toprovide smoother operation of the roof assembly 36 as it moves along thetracks provided by the guide rails 40. The improved guide members 60reduces the noise and vibration typically associated with guide memberscarrying the large weight of the roof assembly in the rails. Referringto FIG. 13, the guide member 60 is shown arranged within a longitudinalmember 42 of the guide rails 40. The guide member 60 includes a rollerassembly 81 carrying the weight of the roof assembly 36 within the guiderails 40 and a bracket 90 supported by the roller assembly 81 fortransmitting the drive from the drive motor to the roller assembly 81for moving the roof assembly between the open and closed positions. Thebracket 90 is disposed within the channel 74 and has cable 96 and wiremounts secured to the bracket 90 by fasteners 99. The channel 74includes a seal assembly 120 providing a seal compartment 122 enclosingthe cable 96 and wire 98 mounts respectively carrying the drive cableand wires from debris.

[0041] A wall 124 separates the channel 74 from a second channel 126.The roller assembly 81 is disposed within the second channel 126.Elongated slots 128 are arranged in the channels 74 for receivingopposing seals 130 that meet one another at a boundary 132. The seals130 meet one another at the boundary 132 but separate from one anotherto accommodate the bracket 90 as it moves along the rail 40. The cable96 and wire 98 mounts have ends that are received within elongatedgrooves 134. The elongated grooves 134 guide the cable and wire as itmoves within a rail specifically, the elongated grooves 134 arenecessary to prevent the cable from buckling as the drive motor drivesthe cable to push the roof assembly to the closed position.

[0042] Referring to FIGS. 13-15, two lower rollers having a horizontalaxis of rotation are supported by the cage 80 of the roller assembly 81on a floor 136 of the rail 40. Upper rollers 84 having a vertical axisof rotation engage the surface of the wall 124 and may be biased againstthe wall 134 by a spring mechanism in the lateral member 86. The roofassembly is stabilized by a roller 140 that is biased in the upperdirection against a sealing 138 of the rail 40. The roller 140 issupported on an arm 142 pivotally attached to the cage 80. A spring 144,which is schematically shown in the figures, urges the arm 142 androller 140 upward. The spring 144 may be a torsional spring or anysuitable spring mechanism known in the art.

[0043] As discussed above, it is desirable to utilize elongated grooves134 to guide the drive cable as it pushes the roof assembly. However,the guide member 60 must travel along an arcuate portion in the supportmembers 44 (best shown in FIG. 8) as the roof assembly moves upward anddownward in closed positions. However, the cable does not want to bendin the elongated grooves 134 and the support members 44 as the rollerassembly 81 moves along the arcuate portion 146. The present inventioncouples the bracket 90 to the roller assembly 81 in such a manner thatthe bracket 90 turns with the roller assembly 81 to bend the cablewithin the curved elongated grooves 134 so that it does not bind withinthe grooves or excessively wear. However, the present invention guidemember also is designed such that the roller assembly 81 can move overdebris within the rail 40 without undesirably rotating the bracket 90was moving along a straight groove.

[0044] Referring to FIGS. 14-16, the roller assembly 81 includes avariably opposing flanges 148 adjacent to the bracket 90. The bracket 90includes spaced apart upper and lower stops 150 on each side of thebracket 90. A flange 148 is arranged between each pair of stops 150 andprovides a gap 152 preferably between the flange and the upper stop topermit upward motion of the roller assembly 81 as it travels over debrison the floor 136 of the rail 40. The gap permits slight relativerotation between the roller assembly 81 and the bracket 90,approximately 3°. The roller assembly 81 includes a protruding member154, which may be part of the lateral member 86, with a bearing 156disposed about the protruding member 154. The bearing 156 is arrangedwithin the aperture 92 and the bracket 90. As the roller assembly 81travels along the arcuate portion 146. The flange 148 will engage thestop 150 and force the bracket 90 along with the mounts 96 and 98 torotate with the roller assembly 81 thereby forcing the drive cable tobend as it moves down the arcuate portion 146. In this manner, wearcaused by the drive cable and cable mounts 96 and 98 within the curvedelongated grooves 134 in the support members 44 is avoided.

[0045] The invention has been described in an illustrative manner, andit is to be understood that the terminology that has been used isintended to be in the nature of words of description rather than oflimitation. The vehicle 10 includes electronic hardware, software, andactuators typically available. The sequence used to open and close theroof panel 16 may be programmed and initiated by operation of a switch.Obviously, many modifications and variations of the present inventionare possible in light of the above teachings. It is, therefore, to beunderstood that within the scope of the appended claims the inventionmay be practiced otherwise than as specifically described.

What is claimed is:
 1. A roof assembly for a vehicle comprising: a roofhaving a roof opening extending to a rear of the roof, the roof havingan exterior surface and forward and rearward ends and a trough extendingbelow the exterior surface on at least one side of the roof openingdefining a path; a first guide member received in the trough and movablealong the path; and a retractable roof panel with a portion supported bythe first guide member and movable along the path, wherein in an openroof position at least a portion of the retractable roof panel extendsabove at least a portion of the roof's exterior surface.
 2. The roofassembly of claim 1 wherein in a closed roof position the roof panel isdisposed within the roof opening, the roof panel defining a rear headerat the rearward end with the rear header moving toward the forward endwhen moving between a closed roof position and the open roof position.3. The roof assembly of claim 1 further comprising spaced apart guiderails supported by the exterior surface.
 4. The roof assembly of claim 3further comprising a second guide member received in at least one of theguide rails and movable along the at least one guide rail, a portion ofthe retractable roof panel in communication with the second guidemember.
 5. A roof assembly for a vehicle comprising: a roof having aroof opening extending to a rear of the roof, the roof having anexterior surface and forward and rearward ends; spaced apart guide railssupported by the exterior surface defining a path; a guide received ineach of the guide rails, and movable along the path, the guide includesa roller assembly received within a channel in each of the guide rails,the roller assembly includes a first roller having a horizontalrotational axis and a second roller having a vertical rotational axis;and a retractable roof panel with a portion supported by the guide andmovable along the path, wherein in an open roof position at least aportion of the retractable roof panel extends above at least a portionof the roof's exterior surface.
 6. The roof assembly of claim 5 whereinin a closed roof position the retractable roof panel is disposed withinthe roof opening, the retractable roof panel defining a rear header atthe rearward end with the rear header moving toward the forward end whenmoving between a closed roof position and the open roof position.
 7. Aroof assembly for a vehicle comprising: a roof having a roof openingextending to a rear of the roof, the roof having an exterior surface andforward and rearward ends; a channel extending below the exteriorsurface on at least one side of the roof opening defining a path; afirst guide member, at least a portion of the first guide memberreceived in the channel and movable along the path; and a retractableroof panel with a portion supported by the first guide member andmovable along the path, wherein in a fully open position the retractableroof panel extends above at least a portion of a driver and frontpassenger section of the vehicle.
 8. The roof assembly of claim 7,comprising a guide rail extending above the exterior surface.
 9. A roofassembly for a vehicle comprising: an exterior surface having fore andaft ends and an opening extending to a rear of the covering means; afirst guiding means extending below the exterior surface and defining afirst path; a second guiding means extending above the exterior surfaceand defining a second path; and a retractable panel having a portionsupported by the first and second guiding means, and movable along thefirst and second paths, wherein in a fully open position the retractableroof panel extends above at least a portion of a driver and frontpassenger section of the vehicle.
 10. A method of moving a retractableroof panel comprising the steps of: a) rotating a first guide supportingthe retractable roof panel from a locked position to an unlockedposition; b) moving the first guide along a first path from the unlockedposition; and c) moving a second guide supporting the retractable roofpanel along a second path that is spaced vertically from the first path,step c) simultaneously performed with step b) to move the retractableroof panel from a close position to an open position.
 11. The methodaccording to claim 10, wherein step b) includes moving the first guidealong a first channel that provides the first path.
 12. The methodaccording to claim 11, wherein step a) includes rotating the first guideout of engagement with a recess in the first channel.
 13. The methodaccording to claim 11, wherein step a) includes rotating the first guideabout a first pivot point provided between the first guide andretractable roof panel and rotating the first guide about a second pivotpoint provided between the first guide and the first path.
 14. Themethod according to claim 10, wherein step a) is performed in responseto actuating a drive element.
 15. The method according to claim 10,wherein step b) includes moving the first guide along the first pathbelow a roof exterior surface, and step c) includes moving the secondguide along the second path above the roof exterior surface.
 16. Themethod according to claim 10, wherein step a) includes moving theretractable roof panel vertically.
 17. The method according to claim 16,wherein a rear of the retractable roof panel engages a rear window inthe locked position, the retractable roof panel spaced from the rearwindow in response to performing step a).